Method for gasifying feedstock with high yield production of biochar

ABSTRACT

A downdraft gasifier and method of gasification with high yield biochar that utilizes a plurality of high throughput, vertically positioned tubes to create a pyrolysis zone, an oxidation zone beneath the pyrolysis zone and a reduction zone beneath the oxidation zone. A rotating and vertically adjustable rotating grate is located beneath the reduction zone of the gasifier. In addition, a drying zone is located above the pyrolysis zone so the heat of the gasifier can be used to dry feedstock before it enters the gasifier. By optimizing the grate height and rpm, feedstock retention time in the drying zone, the drying zone temperature and feedstock moisture content, the result is gasification of biomass with a high yield and continuous biochar production.

RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.16/586,181, filed Sep. 29, 2019, entitled Method for Gasifying Feedstockwith High Yield Production of Biochar, which is a continuation-in-partof issued U.S. application Ser. No. 15/167,452, filed May 27, 2016,entitled Device with Dilated Oxidation Zone for Gasifying Feedstock, nowU.S. Pat. No. 10,465,133; which is a continuation of issued U.S.application Ser. No. 14/222,217, filed Mar. 21, 2014, now U.S. Pat. No.9,375,694, entitled Device with Dilated Oxidation Zone for GasifyingFeedstock; which is a continuation of issued U.S. application Ser. No.13/751,983, filed Jan. 28, 2013, now U.S. Pat. No. 8,721,748, entitledDevice with Dilated Oxidation Zone for Gasifying Feedstock, all of whichare herein incorporated by reference in their entireties.

The invention relates to thermochemical technology and equipment, inparticular, to processes and apparatuses for gasifying solid biomass,household and industrial waste, fossil fuels as well as othercarbon-containing feedstock with a continuous and high yield productionof biochar using downdraft gasification.

BACKGROUND

Gasification is a continuous thermal decomposition process in whichsolid organic or carbonaceous materials (feedstock) break down into acombustible gas mixture. The combustible gas components formed areprimarily carbon monoxide (CO), hydrogen (H2), and methane (CH4). Othernon-combustible gases such as nitrogen (N2), steam (H2O), and carbondioxide (CO2) are also present in various quantities. The process ofgasification involves pyrolysis followed by partial oxidation, which iscontrolled by injecting air or other oxygen containing gases into thepartially pyrolysed feedstock. More specifically, biomass gasificationis a sequence of reactions including water evaporation, lignindecomposition, cellulosic deflagration and carbon reduction. An externalheat source begins the reaction, but partial oxidation provides heat tomaintain the thermal decomposition of the feedstock. If concentratedoxygen is used, the resulting gas mixture is called syngas. If air(which includes nitrogen) is used as the oxidant, the resulting gasmixture is called producer gas. For simplicity, the term “Producer Gas”as used herein shall include both syngas and producer gas. Both gasmixtures are considered a “fuel gas” and can be used as a replacementfor natural gas in many processes. They can also be used as a precursorto generate various industrial chemicals and motor fuels. When biomassis used as the feedstock, gasification and combustion of the ProducerGas is considered to be a source of renewable energy. In addition, lowercost Biochar from biomass waste products (agricultural and forestry orother suitable biowaste materials) is growing in importance andapplication across a variety of industries.

As a general matter, gasification offers a more efficient, costeffective and environmentally friendly alternative for extractingpotential energy from solid feedstock as compared to combustion. As aresult of gasification, the feedstock's potential energy can beconverted to Producer Gas, which is cleaner burning, compressible andmore portable. Producer Gas may be burned directly in some engines andburners, purified to produce methanol and hydrogen, or converted via theFischer-Tropsch and other methods and processes into synthetic liquidfuel.

There are three common gasification processes: fluidized bedgasification, updraft gasification and downdraft gasification. Thepresent invention is an improved downdraft gasifier. Therefore only abrief description of fluidized bed gasification and updraft gasificationare provided and followed by a fuller discussion of current downdraftgasification.

Updraft Gasification

The counter-current fixed bed (“updraft”) gasifier consists of a fixedbed of feedstock on top of a large grate through which steam, oxygenand/or air flow upward. Updraft gasifiers typically require feedstockthat is hardy and not prone to caking or clumping so that it will form apermeable bed. The updraft gasifier consists of a feedstock bed throughwhich the oxidant (steam, oxygen and/or air) flows in from the bottomand exits through the top as gas. Updraft gasifiers are thermallyefficient because the ascending gases pyrolyze and dry the incomingbiomass, transferring heat so that the exiting Producer Gas is cooledwhen it exits the gasifier. However, significant amounts of tar arepresent in the Producer Gas, so it must be extensively cleaned beforeuse, unless it is combusted at the point of generation. The tar can berecycled to the gasifier, but tar removal is complicated and costly. Theupdraft gasifier has been the standard of coal gasification for 150years and it is also popular in biomass cooking stoves.

Fluidized-Bed Gasification

In a fluidized-bed gasifier, oxidant is blown through a bed of solidparticles at a sufficient velocity to keep the solid particles in astate of suspension. The feedstock is introduced to the gasifier, veryquickly mixed with the bed material and almost instantaneously heated tothe bed temperature either externally or using a heat transfer medium.Most of these fluidized-bed gasifiers are equipped with an internalcyclone in order to minimize char (carried over into the Producer Gasstream) and remove fluidizing media from the Producer Gas. The majoradvantages include feedstock flexibility and the ability to easilycontrol the reaction temperature, which allows for gasification of finegrained materials (sawdust, etc.) without the need of pre-processing.Fluidized-bed gasifiers also scale very well to large sizes.Unfortunately, problems with feeding, instability of the bed, build-upof residual carbon and ash sintering in the gas channels occur. Otherdrawbacks include high tar content of the Producer Gas (up to 500 mg/m³gas), relatively low efficiency and poor response to load changes. Dueto high operating and maintenance costs, this style of gasification iseconomically limited to large-scale applications, typically in excess of100 tons per day.

Downdraft Gasification

In downdraft gasification, all feedstock, air and gases flow in the samedirection—from top to bottom. Although updraft gasification is typicallyfavored for processing of biomass feedstock and fluid bed gasificationis typically used in gasification of coal, downdraft gasificationprocess has a number of advantages. One advantage of downdraftgasification is low levels of tar in the resulting Producer Gas becausethe tars generated during pyrolysis must pass through the Oxidation Zone(defined below) and the char bed in the Reduction Zone (defined below)before exiting the gasifier. The high temperature of the Oxidation Zoneand the top of the char bed breaks down the tars (i.e., thermalcracking). The result is a Producer Gas that may be cooled and moreeasily cleaned for use in reciprocating engines, gas-fired turbines andcatalytic reforming processes.

Current downdraft gasification processes have some significantdisadvantages that have prevented widespread adoption. Thesedisadvantages are: (1) the feedstock generally must be pre-processedinto standard sizes with similar chemical properties (without mixingdifferent types of feedstock or different size pieces) to enablecontinuous gasification without bridging (i.e., jamming) the device ordisrupting the quality of the Producer Gas; (2) the feedstock must havea standardized range of volatile components; (3) the feedstock must havea standardized calorific content (i.e., btu/lb); (4) generally, thegasifier must be stopped frequently for cleaning and removal of excesschar that accumulates at the bottom of the gasifier; (5) the ProducerGas created is of inconsistent quality, and the gasifier is lessproductive and less efficient due to temperature changes caused byfrequent shutdowns and variations in feedstock; (6) the gasifiers do notallow for reconfiguration during operation and must be shut down everytime the oxidation reaction shifts from its designated location in thegasifier; (7) the gasifiers are not thermally stable over long periodsof time and lose efficiency (or melt down); and (8) the gasifiers do notallow the location of the oxidation reaction to be moved in tandem withthe reduction zone to compensate for different conditions required togasify different types of feedstock and to generate different ratios ofProducer Gas components. But the most significant disadvantage ofcurrent downdraft gasifiers is that (9) they require hearth loading suchthat the Oxidation Zone, also the hottest zone of the gasifier, bedesigned with a substantial restriction point (i.e., a restriction ofapproximately one half the diameter of the other sections of thegasifier).

In an ideal downdraft gasifier, there are three zones: a Pyrolysis Zone,an Oxidation Zone and a Reduction Zone (each defined below). In such anideal gasifier, (1) the residence time of feedstock could be controlledin the Oxidation Zone (relative to the flow of feedstock through therest of the gasifier) to allow the maximum amount of feedstock toundergo gasification before passing out of the Oxidation Zone into theReduction Zone and (2) the Reduction Zone would be designed to cause thehot gas produced in the Oxidation Zone to mix with the char in theReduction Zone as quickly and as thoroughly as possible to promotethorough gasification. Unfortunately, the restriction area in currentgasifiers greatly impedes the overall volume of feedstock that can bemoved through such a gasifier and disrupts the overall flow and outputof Producer Gas.

The restriction areas found in prior art gasifiers are commonly referredto as the throat and hearth, which are an intentional design in currentdowndraft gasifiers as dictated by the prevailing theory, SuperficialVelocity Theory.

Superficial Velocity (SV) is measured as:SV=Gas Production Rate/Cross Sectional Area=(m³/s)/(m²)=m/swhere s=time and m=distance.

Superficial Velocity Theory, when used to design downdraft gasifiers,dictates that a higher superficial gas velocity in the Oxidation Zonemeans a cleaner Producer Gas and less char by-product will be produced.

The physical restriction required by Superficial Velocity Theory in theOxidation Zone itself limits both the entry and exit of feedstock intraditional downdraft gasifiers. It would be preferable to control thefeedstock's velocity in the restriction area independent of its velocitythroughout the rest of the gasifier in order to promote completegasification and to reduce production of char by-product.

What was needed was a downdraft gasifier design that allows the flowrate of feedstock to be controlled as it passes through the OxidationZone with minimal restriction in order to improve the overall volume andflow of feedstock passing through the gasifier. The downdraft gasifierdevice described in U.S. application Ser. No. 15/167,452, filed May 27,2016, entitled Device with Dilated Oxidation Zone for GasifyingFeedstock; which is a continuation of issued U.S. application Ser. No.14/222,217, filed Mar. 21, 2014, now U.S. Pat. No. 9,375,694, entitledDevice with Dilated Oxidation Zone for Gasifying Feedstock; which is acontinuation of issued U.S. application Ser. No. 13/751,983, filed Jan.28, 2013, now U.S. Pat. No. 8,721,748, entitled Device with DilatedOxidation Zone for Gasifying Feedstock, provide a solution to this need.One shortfall of the above described was that it originally producedbiochar as a byproduct. What is now needed is a method for continuousproduction of biochar using the down draft gasification device.

SUMMARY

The following is a summary description of the invention. It is providedas a preface to assist those skilled in the art to more rapidlyassimilate the detailed discussion, which ensues and is not intended inany way to limit the scope of the claims, which are appended hereto, inorder to particularly point out the invention.

The invention disclosed is a gasifier comprising a plurality ofconjoined and vertically positioned tubes. The tubes have an interiorwall and exterior wall and a proximal and distal end wherein theproximal end provides an inlet and the distal end provides an outlet.The gasifier has three separate reaction zones: (1) a Pyrolysis Zone;(2) an Oxidation Zone beneath the Pyrolysis Zone; and (3) a ReductionZone beneath the Oxidation Zone. A rotating and vertically adjustablegrate is located below, but not attached to, the Reduction Zone. Unlikeother gasifiers, this is a partially open core gasifier without anairtight seal on the distal end of the gasifier. The Producer Gas exitsthrough the grate and is collected by collection vents on the sides ofthe collection chutes.

In addition, a Drying Zone is placed above (or prior in process to) thePyrolysis Zone so the heat of the gasifier can be optionally be used todry feedstock before it enters the gasifier. In operation, feedstock isfed into the Pyrolysis Zone (either directly or by way of the DryingZone). Gravity causes the feedstock to move downward through the threereaction zones, with the Producer Gas and carbon ash and residueby-product formed after a biomass feedstock has been gasified(“Biochar”) exiting through the grate at the bottom of the gasifier intocollection chutes. The Biochar is separated from the Producer Gas bygravity. Now in addition, by introducing novel operational and controlmodifications to the downdraft gasification device, the gasifier can nowbe repurposed to produce a high yield of biochar as a primary product ona continuous basis at a larger scale than typical pyrolysis unitsdesigned specifically for biochar production.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cutaway front view of a gasifier.

FIG. 2 shows a cutaway side view of a gasifier.

FIG. 3 shows the exterior front view of a gasifier.

FIG. 4 shows the exterior side view of a gasifier.

FIG. 5 shows a cutaway front view of a gasifier with dimensions shown ininches.

FIG. 6 shows a cutaway side view of a gasifier with dimensions shown ininches.

FIG. 7 shows a cutaway side view of a gasifier illustrating the densestportion of an induced and an entrained gradient.

FIG. 8 shows a cutaway perspective view of a gasifier illustrating thedensest portion of an induced and an entrained gradient.

FIG. 9 shows a cutaway side view of a gasifier with an oxidation band.

FIG. 10 shows a cutaway perspective view of a gasifier with an oxidationband.

FIG. 11 shows a perspective view of a grate frame.

FIG. 12 shows a top view of a grate frame.

FIG. 13 shows a perspective view of an assembled grate having a spiralgroove.

FIG. 14 shows a front view of an assembled grate having holes cut in thegrate.

FIG. 15 shows a perspective view of removable segment of a grate.

FIG. 16 shows a top view of a removable segment of a grate.

FIG. 17 shows a cutaway side view of a gasifier with arrows depictingthe gasification process.

FIGS. 18-21 show graphs containing findings of the down draft gasifierperformance from a 100-day test run limiting the drying zone temperatureand adjusting the grate height and speed.

DETAILED DESCRIPTION

Definitions

The following list of defined terms is in not intended to be limiting orcomprehensive but merely provide a quick reference tool forunderstanding the invention. Other defined terms are capitalized inother sections of this document where they are used. Capitalized terms,shall include all variants, singular and/or plural versions of the termsused herein.

“Bed Oxidant Stream” or “Bed Air” means the Oxidant Stream entering thegasifier through inlets (i.e., non Plano Air Inlets) positioned at thetop of the Pyrolysis Zone (or the optional Drying Zone).

“Biochar” means the carbon ash and residue by-product formed after abiomass feedstock has been gasified.

“Bypass” means the “gap” between the top of the grate located underneaththe gasifier and the opening at the bottom of the Reduction Zone, whichmay also be referred to as the grate pitch.

“Control System” means an operating system, which includes multiplecontrol mechanisms and coordinated software for a user/operator toadjust variables of a gasifier such as grate rotation and height, inputof feedstock and Oxidant Streams.

“Drying Zone”, with regard to the gasifier, means an area wherefeedstock is dried prior to entering a Pyrolysis Zone, said Drying Zonebeing a container of sorts or extension of the gasifier above thePyrolysis Zone, but alternatively it may be an area and/orcomponent/unit separate from the gasifier. In the context of thegasification process, the “Drying Zone” means the phase where feedstockis dried.

“Gasifier Flow Lane” means the path, generally toward the middle of agasifier, where feedstock moves the fastest, is gasified, and theresulting Producer Gas and Biochar continue to move into a ReductionZone and out of gasifier through a grate.

“Oxidant Stream” means air or other oxygen containing gases.

“Oxidation Band”, with regard to a gasifier, means the location wherethe primary gasification reaction occurs. The Oxidation Band is wherethe Oxidant Streams converge and, together with the heat from thegasifier and the presence of feedstock, the gasifier quickly oxidizesthe feedstock in a narrow band of white hot gas that extends across thediameter of a gasifier. In the context of the gasification process, the“Oxidation Band” means the hottest phase of the gasification reaction.

“Oxidation Zone”, with regard to the gasifier, means a zone of agasifier leading up to and away from an Oxidation Band. The overallshape of the Oxidation Zone is of a hollow tube, the tube having aninlet and an outlet of approximately the same size but is dilated in themiddle. In the context of the gasification process, the “Oxidation Zone”means a phase where feedstock changes to a gas.

“Plano Air Inlets” means pressurized air inlets used to injectpressurized Oxidant Streams into a gasifier. In existing gasifiers,tuyeres are used to allow air to passively enter a gasifier, but PlanoAir Inlets are instead pressurized to inject Oxidant Streams into thegasifier.

“Plano Oxidant Stream” or “Plano Air” means an Oxidant Stream entering agasifier through Plano Air Inlets.

“Pressure Lock” means a pressure lock assembly with a valve at its topand another valve at its bottom, the pressure lock being located at thetop of a gasifier.

“Pressure Wave” means the differential pressure between the center ofthe Oxidation Band and the Oxidation Zone wall, which pushes feedstocktoward the wall of a gasifier forming an induced gradient of feedstockabove the Oxidation Band (“Induced Feedstock Gradient”) and an entrainedgradient of Biochar below the Oxidation band (“Entrained BiocharGradient”).

“Producer Gas” means the combustible gas mixture created by gasificationof feedstock and includes both syngas and producer gas.

“Purge Oxidant Stream” or “Purge Air” means the Oxidant Stream mixedwith feedstock prior to the feedstock entering the Pyrolysis Zone (orthe Drying Zone).

“Pyrolysis Zone”, with regard to a gasifier, means the zone of thegasifier where the feedstock begins to fluidize and decompose beforepassing into the Oxidation Zone. The overall shape of the Pyrolysis Zonemay range from a hollow tube to an inverted hollow cone. In the contextof a gasification process, the “Pyrolysis Zone” means the phase wherefeedstock begins to fluidize and decompose.

“Reduction Zone”, with regard to a gasifier, means the zone of thegasifier where Producer Gas mixes with Biochar, cools and producesadditional Producer Gas. The overall shape of the Reduction Zone is thatof a hollow tube, being wider than the outlet of the Oxidation Zone. Inthe context of the gasification process, the “Reduction Zone” means thephase where Producer Gas mixes with Biochar.

Overview of the Gasifier Zones

The present invention relates to a method and apparatus for gasifyingcarbon-containing biomass feedstock. The gasifier comprises a pluralityof conjoined and vertically positioned tubes. The tubes have an interiorwall and exterior wall and a proximal and distal end wherein theproximal end provides an inlet and the distal end provides an outlet.The gasifier has three separate sequential reaction zones: (1) aPyrolysis Zone; (2) an Oxidation Zone beneath the Pyrolysis Zone; and(3) a Reduction Zone beneath the Oxidation Zone. A rotating andvertically adjustable grate is located below, but not attached to, theReduction Zone. Unlike other gasifiers, this is a partially open coregasifier; there is no airtight bottom wall sealing the Reduction Zone orthe bottom of the gasifier itself.

FIGS. 1 and 2 show a cutaway front view of a gasifier. This downdraftgasifier is a sequential, co-current flow, gravity-assisted,thermo-chemical phase change gasifier having at least three zones: aPyrolysis Zone 20, an Oxidation Zone 30 and a Reduction Zone 40. Thegasifier partially oxidizes a portion of the feedstock, which releasesenough heat activation energy to start a thermo-chemical solid-to-gasphase change reaction of the remaining feedstock into Producer Gas. Theprocess of gasification is a sequence of reactions including waterevaporation, lignin decomposition, cellulosic deflagration and carbonreduction and is controlled by injecting Oxidant Streams into thepartially pyrolysed feedstock. Although the present invention will bedescribed in the context of a method and apparatus for processingbiomass, the principles described may be applied to many other types offeedstock and various embodiments will be readily apparent to thoseskilled in the art.

The interior of the entire gasifier is lined with silica carbide, silicaoxide, aluminum oxide, refractory alloys, other ceramics or anothermaterial having similar properties that is stable at high temperatures.Non-volatile and ungasified materials are separated from the ProducerGas by gravity as these materials fall to the bottom of the gasifier.This high efficiency gasifier converts the chemical potential energy offeedstock into Producer Gas, with the average amount of Biochargenerated being about 1%-10% by weight of the original feedstock.

FIGS. 3 and 4 show the exterior front and side views of a gasifier.Feedstock moves downward in the gasifier as gasification takes place. Asthe gasifier reaches a steady operating state (i.e., the state whereineach zone of the gasifier has reached a steady and sustainedtemperature), a vertical temperature gradient forms inside the gasifierand the feedstock stratifies into a sequence of layers or zones roughlycorresponding to the Pyrolysis Zone 20, the Oxidation Zone 30 and theReduction Zone 40 based on the steps in the gasification process. Thereare no fixed boundaries between these zones, but instead the boundariesare contiguous. Therefore there are transitional gradients having mixedproperties of each of the adjacent zones (i.e., feedstock pyrolysis maybegin in the Drying Zone 10 and oxidation may begin in the PyrolysisZone 20). Feedstock is maintained at a level above the Pyrolysis Zone 20and pulled down through the Pyrolysis Zone 20 by gravity so thatdescending feedstock replaces feedstock that has been gasified. Gasesand feedstock flow in a downward direction inside the gasifier. Solidmaterials flow through the gasifier by gravity. Gases move downwardthrough the gasifier by pressure differential.

Solids (e.g., feedstock and Biochar) are held inside the gasifier by avertically adjustable, rotating grate 50 located just below theReduction Zone 40 of the gasifier, as shown in FIGS. 1, 2, 3 and 4. Theresidence time of solids within the gasifier is controlled by therotational speed of the grate 50, the vertical position of the grate 50,and the rate of gasification (i.e., phase change) within the gasifier.The Biochar accumulates on top of the grate 50 and acts as a pseudo-sealfor the bottom of the gasifier, which then allows the gasifier topressurize, and maintain pressurization even as Biochar continuouslyleaves the gasifier. Biochar falls from the bottom of the gasifierthrough the rotating grate 50 or out the Bypass 49. Once the Biocharfalls from the grate 50 or the Bypass 49, it falls into one or morecollection chutes 60 below the grate 50 and then into a residue box 90,where it is removed from the gasifier by an auger 91.

In one embodiment, the zones of the gasifier include: the Drying Zone10, the Pyrolysis Zone 20, the Oxidation Zone 30, the Reduction Zone 40with a grate 50 located underneath the gasifier. Below the gasifier aregas collection vents 70, Biochar collection chutes 60 and a Biocharresidue box 90.

FIGS. 5 and 6 show a cutaway front and side view of a gasifier withdimensions.

The Drying Zone

Overall Description, Size and Functioning.

In the Drying Zone 10, moisture within the feedstock is evaporated as itis exposed to radiant heat emitting from the Oxidation Zone 30. Thewater vapor flows downward through the Pyrolysis Zone 20 toward theOxidation Zone 30 along with the Bed Oxidant Stream and the PurgeOxidant Stream being fed into the gasifier. Temperatures in the DryingZone 10 can vary extensively depending on how the gasifier is operated.By way of example, for woodchips with 25% moisture content, the normalrange of temperature in the Drying Zone 10 is about 100 to 300° F. Thedepth of the Drying Zone 10 in one embodiment may be between zero andsix feet tall. This depth may increase with the moisture content of thefeedstock, the size of the gasifier and the embodiment of the gasifierused. Radiant heat from the Oxidation Zone 30 drives the evaporativeprocesses. However, preheating the Bed Oxidant Stream and the PurgeOxidant Stream can accelerate the drying process.

Drying the feedstock inside the gasifier is an endothermic process, andso energy (i.e., heat) is required to dry and release water from thefeedstock as steam, which steam assists the reactions occurring below.The wetter the feedstock, the more energy the Drying Zone 10 requires.

-   -   The primary physical change in the Drying Zone 10 is:        H₂O_((l))+Heat H₂O_((g))    -   Wherein “H” is Hydrogen, “O” is oxygen, “l” is liquid, and “g”        is gas.        Description of the Feeding Mechanism and Fill Level Indicators

Because the gasifier becomes pressurized during operation, a PressureLock may be used to bring feedstock into the gasifier while maintainingthe gasifier's pressure. A top valve of the Pressure Lock opens to admitfeedstock into the Pressure Lock and then closes. The interior of thePressure Lock pressurizes to match the air pressure of the PyrolysisZone 20 (or optional Drying Zone 10), which may be controlled by a userthrough the Control Systems, before a bottom valve opens allowing thefeedstock to leave the Pressure Lock and enter the gasifier at theadjusted air pressure.

The Pressure Lock may be fabricated from materials such as Schedule 40seamless carbon steel pipe, 150 pound class steel flanges and standard150 pound class slide gate valves, such as knife-gate valves. ThisPressure Lock assembly may be integrated into the equipment design anduse a pair of standard industrial knife-gate valves with a pipe betweenthem. The pipe in one embodiment may be 18″ schedule 40 pipe orientatedvertically. The length of the pipe may be adjusted depending on thefeedstock delivery method and desired volume. An example of a PressureLock is 72″ in length, which will provide 100-120 pounds of feedstockper feedstock dump into the Drying Zone 10 (where applicable) or thePyrolysis Zone 20. In one embodiment, attached to the pipe are threadedcouplings for receiving (1) a level switch, such as a rotary levelswitch, limit switch, photon switch, or a laser switch, and (2) apressure transmitter, and (3) a pressurized air supply line.

The end user may automate the gasifier feedstock filling process with atimer or by using a microwave sensor or another suitable fill levelindicator, to detect the presence of feedstock at the fill level in thegasifier and also in the Pressure Lock (“Fill Level Indicators”). TheDrying Zone 10 of the gasifier may have one or more Fill LevelIndicators capable of functioning in high temperature environments. Oncethe Fill Level Indicator 12 detects that the feedstock level is low, theautomatic feed mechanism begins. One gasifier design with multiple FillLevel Indicators 12 allows more options in choosing the height of thefeedstock bed when using an automatic filling system.

In one embodiment, the top valve of the Pressure Lock opens and a bucketloading mechanism dumps feedstock into the Pressure Lock until a FillLevel Indicator in the Pressure Lock detects that it is full. The topvalve of the Pressure Lock closes and the Pressure Lock pressurizes tomatch the pressure of the Drying Zone 10 (if applicable) or thePyrolysis Zone 20. Then, the bottom valve of the Pressure Lock opens anddeposits the feedstock onto a pressurized auger that is connected to theDrying Zone 10 (where applicable) or the Pyrolysis Zone 20. The augerthen deposits the feedstock into the top of the gasifier. The gasifier'scontrol systems determine when to initiate each feedstock fill cyclebased on the signals, such as temperature or pressure changes, receivedfrom various sensors and indicators on the gasifier.

The Pyrolysis Zone

Overall Description, Size and Functioning

The Pyrolysis Zone 20 is directly below the Drying Zone 10 (where aDrying Zone 10 is included) within the gasifier. The Pyrolysis Zone 20may be increased or decreased in height based on the properties of thepredominant type of anticipated feedstock. A taller Pyrolysis Zone 20will accommodate wetter and/or more complex materials that require moredrying and longer pyrolysis times.

In the Pyrolysis Zone 20, vapors, oils, and constituent gases aredistilled and moved downward by the effects of gravity, pressuredifferences and steam created in the Drying Zone 10 and the PyrolysisZone 20. The Pyrolysis Zone 20 is endothermic at the top and relies onheat released from below. Toward the bottom of the Pyrolysis Zone 20,where the temperature increases, the feedstock begins to spontaneouslybreak down as it becomes chemically unstable at the elevatedtemperatures. Therefore, the decomposition of feedstock occurring in thelower section of the Pyrolysis Zone 20 is exothermic and releases heat.In one embodiment, the Pyrolysis Zone 20 is four to six feet deep.

Pyrolysis chemistry is highly complex. The principal chemical andphysical changes occurring in this zone can be simplified andrepresented by the following:C_(x)HyO_(z)(s)+Heat Organic Vapors(formaldehyde, alcohols, tars, etc.)C_(x)H_(y)O_(z)(s)CH₄+H2+C(s)+Organic Vapors(tars)+Heat

Because some Oxygen is present in the Pyrolysis Zone 20 from the OxidantStreams being fed into the gasifier, oxidation may occur as feedstockapproaches the bottom of the Pyrolysis Zone 20.

The Oxidation Zone

Overall Description, Size and Functioning

The Oxidation Zone 30 is the zone in the gasifier leading up to and awayfrom the Oxidation Band 350 or the general step of the method includingformation of the Oxidation Band 350. The Oxidation Zone 30 is where theOxidation Band 350 forms and represents the hottest step in thegasification process and is where the cellulosic fraction of thefeedstock converts from a solid to a gas.

The First Gradient (The Induced Feedstock Gradient)

Shown in FIGS. 7 and 8, during operation, the flow of an Oxidant Streamthrough Pyrolysis Zone 20 induces a feedstock gradient to form (1)vertically, beginning toward the top of the outside wall of thePyrolysis Zone 20 and ending down at a lower ring of Plano Air Inlets 32in the Oxidation Zone 30 and (2) horizontally, beginning in the centerof the gasifier and ending at the wall of the gasifier (the “InducedFeedstock Gradient”).

As shown in FIGS. 7, 8, 9, and 10, this Induced Feedstock Gradient is anincreasing and differential density of feedstock becoming denser towardthe perimeter of the gasifier wall and above the Oxidation Band 350 (the“Densest Portion”) formed by at least four factors acting in concert:(1) the Pressure Wave from the Oxidation Band 350 pressing feedstockagainst the interior wall of the gasifier; (2) the geometry of thePyrolysis Zone 20 and the Oxidation Zone 30 (i.e., angles of the walls);(3) the total volume of the Oxidant Stream flowing into the PyrolysisZone 20 and the Oxidation Zone 30; and (4) the relative volume of theOxidant Stream flowing into each of the Pyrolysis Zone 20 and theOxidation Zone 30. The Densest Portion of the Induced Feedstock Gradientis illustrated at 200.

Feedstock travels through the gasifier at different velocities. Some ofthe feedstock is steadily progressing down the gasifier in the GasifierFlow Lane 203, while other feedstock may pause or slow at various pointsin the gasifier. Feedstock moves more slowly and/or is suspended withinthe Induced Feedstock Gradient 200. The Densest Portion of the InducedFeedstock Gradient 200 is denser and slower moving feedstock than thefeedstock in the Gasifier Flow Lane.

The Densest Portion of the Induced Feedstock Gradient 200 ends at thelower Plano Air Inlets 32 where the Oxidation Zone 30 dilates to a widerdiameter. In one embodiment, this dilation is designed to be aKline-Fogelman step in order to direct and control the rate of flow ofgases and solids moving down the gasifier.

Ordinarily, as gases cross a step such as a Kline-Fogelman step, an eddyis formed. The lower ring of Plano Air Inlets 32 in the Oxidation Zone30 inject air into the location where the eddy would otherwise form.This incoming air stream collides with the Producer Gas and feedstockcoming down the Gasifier Flow Lane 203, redirects hot gases away fromthe wall of the gasifier, counteracts the formation of an eddy, andfuels the Oxidation Band 350.

As conditions in the gasifier change, the Induced Feedstock Gradient mayalso change allowing for movement of the Oxidation Band 350 and theGasifier Flow Lane 203 inside the gasifier. This is not possible inother gasifiers where the Gasifier Flow Lane 203 would be formed againstthe immovable outer wall of the gasifier.

The Oxidation Band

Shown in FIGS. 9 and 10, the feedstock in the Gasifier Flow Lane 203travels down through the gasifier into the Oxidation Band 350. TheOxidation Band 350 is the point where significant heat is liberated bythe deflagration of the cellulose matter in the feedstock. Onceinitiated during start-up, the Oxidation Band 350 is sustained by theaddition of Oxidant Streams from the Plano Air Inlets 31, 32 andfeedstock descending from above. The Oxidation Band 350 partiallyoxidizes the feedstock into Biochar and constituent gases of ProducerGas. Tar vapors generated in the Pyrolysis Zone 20 are furtherdecomposed in the presence of steam under the high temperatures of theOxidation Band 350 into additional Producer Gas.

As shown in FIGS. 7, 8, 9 and 10, the overall shape of the OxidationZone 30 is of a hollow tube, the tube having an inlet 301 and an outlet303 of approximately the same size but is dilated in the middle 302.This is the opposite of traditional downdraft gasifiers where theOxidation Zone narrows into a restriction point according to SuperficialVelocity Theory.

In one embodiment, the inlet 301 and the outlet 303 of the OxidationZone 30 are half the diameter of the dilated section 302 of theOxidation Zone 30. There are at least two rings of Plano Air Inlets 31,32. In one embodiment, a higher ring 31 being approximately 11 inchesabove the lower ring 32 and a lower ring of Plano Air Inlets 32 being atthe widest part of the dilated section 302 of the Oxidation Zone 30.

The extremely high temperatures generated by this Oxidation Band 350produce the heat that drives the chemical and physical reactions in thePyrolysis Zone 20 and Drying Zone 10 above (if applicable). TheOxidation Band 350 naturally tends to move upward in the gasifier towardthe unconsumed feedstock and the Oxidant Stream supply above. Below theOxidation Band 350 is a mixture of Biochar, which is relatively stableat high temperatures. The gasifier is designed to allow the OxidationBand 350 to move up and down within the gasifier. In one embodiment, theOxidation Band 350 may be held in place in the gasifier by using a grate50 (located below the Reduction Zone 40) to remove the Biochar beneaththe Oxidation Band 350, counteracting the tendency of the Oxidation Band350 to move upward. Whenever the grate 50 stops rotating, the OxidationBand 350 starts rising.

In one embodiment, a higher ring of Plano Air Inlets 31 positioned abovethe lower set of Plano Air Inlets 32, allows additional Oxidant Streamsto be injected to the feedstock just before it enters the Oxidation Band350. Using the rotational speed of the grate 50, the rate and ratio ofthe Bed Oxidant Stream, the Purge Oxidant Stream and the Plano OxidantStreams, the Oxidation Band 350 can be held at any desired locationwithin the gasifier. In one embodiment, the Oxidation Band 350 is heldjust below the lower ring of Plano Air Inlets 32.

The partial oxidation of feedstock is also complex but can be simplifiedinto the following expressions:Feedstock-Bound C+½O₂CO+HeatFeedstock-Bound C+O2CO2+HeatFeedstock-Bound H+O2H2O+HeatFeedstock-Bound H−H₂CO+3H₂CH₄+H₂O+HeatCO₂+4H₂-CH₄+2H₂O+HeatSolid C Residue+2H₂CH₄+Heat CO+H₂O CO₂+H2+Heat

The reactions in the Oxidation Zone 30 are exothermic and release theheat that operates the entire gasifier.

The Second Gradient (the Entrained Biochar Gradient)

Also shown in FIGS. 7, 8, 9 and 10, just below the Oxidation Band 350,the beginning of a second gradient of Biochar forms (1) vertically,beginning just below the lower ring of Plano Air Inlets 32 in theOxidation Zone 30 and extending down along the wall of the OxidationZone 30 into the Reduction Zone 40 (2) horizontally, from the center ofthe gasifier to the wall of the gasifier (the “Entrained BiocharGradient”). As Biochar leaves the Oxidation Band 350, the diameter ofthe Oxidation Zone 30 narrows to approximately the same size as theinlet 301 to the Oxidation Zone 30. The Pressure Wave from the OxidationBand pushes the Biochar against the narrowing wall of the OxidationZone. The Densest Portion of the Entrained Biochar Gradient isillustrated at 300. The Pressure Wave slows the movement of the DensestPortion of the Biochar in the Entrained Biochar Gradient 300 relative toBiochar in the Gasifier Flow Lane 203. The Gasifier Flow Lane 203remains intact even though the feedstock has changed phase, and ProducerGas and Biochar are now moving downward instead of feedstock.

The Densest Portion of the Entrained Biochar Gradient 300 runs downalong the wall of the Oxidation Zone 30 into the Reduction Zone 40. Asthe Reduction Zone 40 is wider than the Oxidation Zone 30, the entranceto the Reduction Zone 40 forms another step. In one embodiment, theangled of the wall of the Oxidation Zone 30 and the inlet to theReduction Zone 40 form a Kline-Fogleman step. As the Producer Gascrosses the step into a wider Reduction Zone 40 (i.e., a diameterexpansion in the Reduction Zone 40), an eddy forms in the Reduction Zone40. This eddy encourages mixing between the Producer Gas and Biochar inthe Reduction Zone 40.

Simulation of a Throat and Hearth

Unlike traditional downdraft gasifiers, this downdraft gasifier does nothave a restriction zone in the Oxidation Zone 30, but instead theOxidation Zone 30 increases in size. Nearly all current downdraftgasifiers apply the Superficial Velocity Theory and are, therefore,constructed with a restriction in the Oxidation Zone 30 in order toachieve a useable quality Producer Gas. Additionally, most currentdowndraft gasifiers use a vacuum to pull Producer Gas through thegasifier.

The two gradients that are formed in this gasifier, the InducedFeedstock Gradient above the Oxidation Band 350 and the EntrainedBiochar Gradient below the Oxidation Band 350 work together to simulatea throat and hearth inside the gasifier. The advantages of this approachare that the Oxidation Band 350 can move up or down in the gasifierwithout damaging or possibly destroying the gasifier itself, and theinside of the gasifier can adapt to different types and mixtures offeedstock. Other gasifiers with a fixed throat and hearth must becalibrated to a small range of feedstock, cannot be easily adjusted toaccommodate other feedstock types, and cannot be adjusted duringoperation to accommodate changes.

The Reduction Zone

Overall Description, Size and Functioning

As shown in FIGS. 1, 2, 7, and 8, the Reduction Zone 40 of the gasifieris equal to or greater in diameter than the outlet 303 of the OxidationZone 30. The two primary functions of the Reduction Zone 40 are togasify residual carbon from the Biochar and to cool the Producer Gas.Both functions occur by the same mechanism, namely the endothermicreactions of Producer Gas constituents and the solid carbon containedwithin the Biochar.

As discussed above, when Producer Gas and Biochar enter the ReductionZone 40, a turbulent eddy forms across the step between the OxidationZone 30 outlet 303 and the wider Reduction Zone 40. This turbulence inthe Reduction Zone 40 causes much better mixing of Producer Gas withBiochar in the Reduction Zone 40 than in other gasifier designs. Thisallows for nearly complete gasification of the carbon in the bed, andmaximizes the cooling effect. In one embodiment, the Reduction Zone 40of the gasifier maintains about a 2 to 6 foot grate above the grate 50.

Producer Gas exits typical downdraft gasifiers at temperatures around1,500° F. or higher. Producer Gas exits this gasifier at temperaturesless than 1,500° F. In one embodiment, it exits at temperatures lessthan 1,000° F. Also, the thick bed of Biochar allows about 90 to 99% ofthe fuel carbon to exit this gasifier as Producer Gas, depending on thefeedstock.

The reduction reactions occurring in downdraft gasifiers have been wellstudied and are understood to involve:Carbon+CO₂+Heat 2COCarbon+H₂O+Heat CO+H2Carbon+2H₂O+Heat CO2+2H2CO₂+H2+Heat CO+H₂OThe Gasifier Grate

The grate 50 of the gasifier may be made of stainless steel or anothersuitable material that is both durable, heat resistant and non-reactivesuch as silica carbide, silica oxide, aluminum oxide, refractory alloysor other ceramics, the grate having a top and a bottom face. In oneembodiment and shown in FIGS. 3 and 4, the bottom face of the grate andshaft may be mounted on an elevating platform 80 that moves up and downand is controlled by variable control systems. As shown in FIGS. 3 and4, the top face of the grate 50 is positioned below the lower edge ofthe Reduction Zone 40. In one embodiment, the Bypass is a gap of 0.25 to2 inches between the Reduction Zone 40 and the top face of the grate 50.

The Spiral Groove

FIG. 11 shows the gasifier grate 50 which provides support for all ofthe solids in the gasifier. In one embodiment, the grate 50 has a frame505 and two faces, a top face and a bottom face.

FIGS. 11 and 12 show the top face of the grate 50 has a spiral groove501. The spiral groove 501 is oriented in the gasifier so that it facesthe Reduction Zone 40. The spiral groove 501 has a starting point at thecenter of the grate and a tail continuing outward to the edge of thegrate 50. Therefore in one embodiment the spiral grove spans the entiretop face of the grate. The purpose of the spiral groove 501 is that itnaturally moves Biochar outward from the center of the grate 50 to theedge of the grate 50 as the grate 50 rotates opposite the direction ofthe spiral groove 501. The Biochar follows the tail of the spiral groove501 as the grate 50 turns in the opposite direction until the Biochar isforced from the Reduction Zone 40 through the Bypass.

In one embodiment of the Reduction Zone 40, silica carbide, silicaoxide, aluminum oxide, a refractory alloy, other ceramics or some otherheat resistant, high density, course material, lines the walls of theReduction Zone 40. This heat resistant, high density, course materialacts as file to grind away at any Biochar that is pressed against anddragged along the outer wall of the Reduction Zone 40 by the rotatinggrate 50. This combination of having a spiral groove 501 in the grateforcing Biochar toward and along the course wall of the Reduction Zone40 assists in grinding large chunks of char into small enough piecesthat they escape the Bypass. A person having ordinary skill in the artwill recognize that different types of spirals may be used (e.g.,Archimedean, logarithmic, etc.).

In one embodiment, the spiral groove 501 in the grate is a “v” shapedArchimedean groove 502, where the outer edge of one groove in the spiralmeets the inner edge of the adjacent groove to form a raised edge. Apurpose of the “v” shaped groove is to avoid having any 90° angles,which would otherwise create hot spots or thermally unstable sections ofthe grate 50.

Raising and Lowering the Grate/Bypass

In one embodiment, the grate 50 can be raised and lowered to create ahigher or lower Bypass, allowing larger items that have inadvertentlyentered the gasifier and/or materials that have not gasified to beremoved without shutting the gasifier down (e.g., brick, rocks, etc.).In an embodiment with a spiral groove 501 in the grate 50, these foreignbodies will be forced to the wall of the Reduction Zone 40, and then thegrate 50 can be lowered to allow them to be discharged through theBypass. This design allows for the gasifier to remain in service andstill remove large, ungasified objects from the Reduction Zone 40. Theability to raise and lower the grate 50 can also be used if maintenanceis ever required inside the gasifier. In addition, the Bypass 49functions to control Producer Gas flow out of the Reduction Zone 40, theBypass 49 acting similar to a valve. For example, a short Bypassincreases resistance to Producer Gas flow through the grate 50 andcauses pressure to build in the gasifier.

Elliptical Holes in the Grate

FIGS. 13 and 14, show the assembled grate. FIGS. 15 and 16 show thegrate “pie slice” segments 502. FIGS. 13 and 14 show a perspective andfront view of an assembled grate having elliptical holes 503. In oneembodiment the elliptical holes 503, such as kidney-shaped oroval-shaped holes are distributed symmetrically across the grate 50(except there are no holes in the center of the grate above themechanical shaft that lifts and rotates the grate). The purpose of theholes 503 is both to allow Biochar and Producer Gas to pass through thegrate into the Biochar collection chute 60 below.

Pie Slice Inserts to the Grate

In one embodiment, the “pie slice” segments 502, 504, sit on a frame 505of the grate 50. When each of the segments 504 is inserted into theframe 505, the grate is formed. This embodiment allows for replacementof a segment 504 rather than the entire grate 50 in the event part ofthe grate 50 becomes damaged, and also allows the gasifier to be fittedwith customized segments 504 designed for particular types of feedstock.

Grate with Multiple Features

FIG. 15 shows a perspective view of removable segment of a grate. In oneembodiment, the grate 50 also has a spiral groove 501 cut as a “v” 502and elliptical, kidney or oval-shaped holes 503 cut through the spiralgroove 501. FIG. 16 shows a top view of a removable segment of a grate.

Controlling the Gasifier Using the Grate

The shaft supporting and rotating the grate 50 can be formed of one ormore pieces, depending on the size of the grate 50. The rotational speedof the grate 50 may be calibrated by a Control System, but typicallyranges from 0.0001 RPM to 1 RPM, depending on the non-volatilecomponents of the feedstock and the rate of production of Producer Gas.Since the 350 effectively rides on top of the bed of Biochar in theReduction Zone 40, if the bed of Biochar in Reduction Zone 40 gets toothick, the Oxidation Band 350 will rise into the Pyrolysis Zone 20.Using thermocouples or other sensors to monitor the location of theOxidation Band 350, the gasifier's Control System discussed below can beprogrammed to speed up the rotation of the grate 50 and remove Biocharat a higher rate, which reduces the height of the Biochar bed and lowersthe Oxidation Band 350 back to appropriate locations. Conversely, thegasifier's Control System can slow the grate 50 if the bed of Biocharbecomes too shallow and, consequently, the Oxidation Band 350 moves tooclose to the grate.

Char Collection Chute

Shown in FIGS. 1, 2, 5 and 6, below the gasifier is a Biochar collectionchute 60, which may be made of steel, stainless steel or another strong,thermally stable, nonporous material. As Biochar exits the bottom orsides of the grate 50, it falls down the Biochar collection chute 60below the gasifier. The Biochar collection chute 60 is arranged at anangle from the direction of the flow of Biochar in the Gasifier FlowLane 203. In one embodiment, the angle is less than 90°, measured fromthe direction of Biochar flow in the Gasifier Flow Lane 203. In oneembodiment, the angle is 45° to 80°, measured from the direction ofBiochar flow in the Gasifier Flow Lane 203. In one embodiment, at leasttwo Biochar collection chutes 60 are symmetrically arranged with respectto center axis of the gasifier.

Producer Gas Collection Vents/Horns

Shown in FIGS. 1, 2, 5 and 6, two or more Producer Gas collection vents70 are positioned within the Biochar collection chute 60 symmetricallyaround the axis of the grate 50. The opening to the Producer Gascollection vents 70 faces downward so the Biochar does not fall directlyinto them as the Biochar falls from the grate 50. As the Producer Gasand Biochar fall into the Biochar collection chute 60, the Biocharseparates from the Producer Gas by gravity, and the Producer Gas exitsthrough the Producer Gas collection vents 70.

The Biochar Residue Box

Shown in FIG. 6, the Biochar residue boxes 90 are at the bottom of theBiochar collection chutes 60. The Biochar falls down a Biocharcollection chute 60 into a Biochar residue box 90.

The Biochar residue box has a tube-style auger 91 called the “ResidueAuger.” The Residue Auger 91 moves the Biochar into a pocket valve 92that is bolted to the end of a cross pipe spool, which is bolted to theResidue Auger 91. In one embodiment, the pocket valve 92 is a standard,air-actuated 8″ or 10″ ball valve where the ball is sealed on one end.When in the “up” position, the ball forms a bucket. The Residue Auger 91is controlled by the gasifier's Control System so that while the pocketvalve 92 is in the up position, the Residue Auger 91 deposits Biocharinto the pocket valve 92. When the Control System stops this process,the Residue Auger 91 stops and the pocket valve 92 rotates to the “down”position, dumping its contents into an external collection bin or someother secondary removal system. Because the ball on the pocket valve 92is closed on one end, the pocket valve 92 remains sealed at all timesand prevents Producer Gas from leaking out of the Biochar residue box90. A small amount of Producer Gas does escape, but can be vented safelyby a high-point vent pipe or drawn out by vacuum pump.

Feedstock Requirements

The gasifier can gasify a very broad range of feedstock. To determinewhether a given feedstock or blend of materials will gasify effectively,the feedstock must be porous enough to allow Oxidant Stream to flowthrough it, have a suitable calorific density (btu/ft³), have a suitablebulk density and a suitable chemical makeup. A person having ordinaryskill in the art would recognize a suitable feedstock. In one embodimentof the gasifier, a suitable feedstock may be: (1) 25% or morechemically-bound oxygen content (molecular basis), (2) 10% or less ashcontent, (3) 30% or less moisture content, and (4) greater than 15lbs/ft³ bulk density. There is some interaction between these variables.

All forms of biomass contain the basic chemical structure ofC_(x)HyO_(z). This molecular structure is inherently unstable atelevated temperatures and will readily break down when heated. This isthe fundamental driver of all types of biomass gasifiers. This molecularbreakdown is highly exothermic and produces the heat necessary tosustain the further breakdown of biomass. Therefore, practically allforms of biomass are suitable feedstock for the gasifier, provided theymeet the porousness and bulk density requirements.

Startup and Shutdown

On start-up, the gasifier is filled up to the middle of the OxidationZone 30 with feedstock. A layer of hot charcoal (in one embodiment alayer just a few inches in height) is added to the top of the feedstockthrough the top of the Pyrolysis Zone 20 or Drying Zone 10 (whereapplicable). The gasifier is then filled with feedstock to thegasifier's Fill Level Indicator and the gasifier's Control System isstarted.

Over the next several hours, the gasifier will begin to heat up, and athermal gradient will start forming. Some low quality gas will be madealmost immediately and Producer Gas production will gradually increaseand improve as the gasifier heats up.

If the gasifier is operated for an adequate period of time, the lininginside the gasifier will become saturated with heat and the gasifier canbe restarted without additional hot charcoal even after several hours ofdowntime. This is referred to as a “warm-start”. In many cases, thegasifier can be shut down for more than 2-3 days and still retain enoughinternal heat for a warm start simply by restarting the Oxidant Streams.Producer Gas flow from the gasifier stops when the Oxidant Streams stop.

Gasifier Control System

Optimizing the gasifier's operation requires precise real-timeadjustments to control the location of the Oxidation Band 350. Forexample, if a mechanical device were inserted in the Oxidation Band 350to adjust the rate of the materials leaving or entering, the 3,000° F.temperatures (approximate) in the Oxidation Band 350 would destroy themechanical device. Therefore, a grate 50 is used to control the removalof Biochar from the gasifier as it can be placed adjacent to the muchcooler Reduction Zone 40. The changes to the height of the Biochar bedcaused by increasing the rate of removal of Biochar from the ReductionZone 40 induce some of the necessary changes to adjust the verticallocation of the Oxidation Band 350. The variables mentioned below mayeach be adjusted to induce changes in the Oxidation Band 350.

Several methods and systems may be used as part of the overall ControlSystem to induce changes to and to control the Oxidation Band 350. TheControl System uses various algorithms to monitor and adjust thegasifier. The Control System may include subsystems capable of real-timeadjustments and account for other methods that may only be adjustedwhile the gasifier is offline. Adjustments while the gasifier is offlinemay include: (1) adjusting the physical size and height of the DryingZone 10 (or removing it); (2) adjusting the size of the holes 503 in thegrate 50 (in one embodiment, by replacing its interchangeable segments504). The Control System may include subsystems to implement real-timeadjustments during operation of the gasifier related to: (a) the type offeedstock entering the gasifier; (b) the rate that feedstock enters thegasifier; (c) the fill level of the feedstock in the Drying Zone 10, ifapplicable; (d) the temperature of the Drying Zone 10, where applicable;(e) the volume, speed and pressure of Oxidant Stream delivered throughthe inlets at the top of the Pyrolysis Zone 20 (or Drying Zone 10, ifapplicable); (f) the volume, speed and pressure of Oxidant Streamdelivered through the rings of Plano Air Inlets 31, 32; (g) the overallpressure of the gasifier; (h) the differential pressure between thevarious zones of the gasifier; (i) the location of the Oxidation Band350 in the gasifier; (j) adjusting the rotational speed of the grate 50;(k) the vertical position of the grate 50 (i.e., adjusting height of theBypass); (1) the thickness of the Biochar bed in the Reduction Zone 40;(m) testing and sampling the constituent components of the Producer Gasexiting the gasifier; (n) the temperature of the Producer Gas exitingthe gasifier; and (o) the Producer Gas collection vent pressure and thepressure of the Producer Gas leaving the gasifier (the above examples,being “Variables”).

Variable Frequency Drives

In one embodiment of the gasifier, the Control System can graduallyincrease or decrease a Variable or start or stop any changes to theVariable entirely. For example, the Control System may need to slightlyslow the rotational speed of the grate 50 at one time and thencompletely stop it at another point. As a person having ordinary skillin the art will recognize, electric motors and drives operate in twogeneral ways some are fixed speed drives and others are variablefrequency (speed) drives (“VFDs”). In one embodiment of the gasifier, aVFD is therefore attached to an on/off timer and used to control therotational speed of the grate 50. By starting and stopping the VFD, theControl System may simulate a slow grate 50 rotation while maintainingsufficient torque from the VFD to rotate the grate 50.

In other applications, such as the Oxidant Stream control system, wherea higher torque is not required, the VFD may be used without an on/offtimer.

Grate Control

The Control System adjusts the rotational velocity of the grate 50 toadjust several of the Variables, including the differential pressurebetween the Oxidation Zone 30 and the Reduction Zone 40. An example ofthe latter is that the differential pressure of the Reduction zone maybe maintained by simply controlling the RPM setting of the grate 50.

Oxidant Stream Flow Control

The rate at which Biochar leaves the gasifier also controls the verticaldifferential pressure across the gasifier (the thickness of the Biocharbed partly determines the pressure of the gasifier because the Biocharforms a pseudo-seal at the bottom of the gasifier). The verticaldifferential pressure across the gasifier, from the top of the DryingZone 10 through to the bottom of the grate 50 is therefore controlled,in part, simply by increasing or decreasing the rotational speed of thegrate 50, which ejects Biochar from the Reduction Zone 40. Describedanother way, if Biochar is not ejected fast enough from the gasifier itaccumulates in the Reduction Zone 40 and the decreased remaining volumeincreases the pressure of the Producer Gas in the Reduction Zone 40 andthe Oxidation Zone 30. In one embodiment, the vertical differentialpressure of the gasifier is controlled by the height of the Bypass; asthe height of the Bypass increases (i.e., by lowering the grate 50) thegreater the flow of Producer Gas and Biochar from the gasifier.

The rate of Producer Gas generation is proportional to the concentrationof Oxygen in the Oxidant Streams and the flow rate of the OxidantStreams being introduced to the gasifier. The Control System measuresand regulates the Oxidant Streams using standard methods known in theart.

FIG. 17 shows a cutaway side view of a gasifier with arrows depictingthe gasification process. Three types of Oxidant Streams enter thegasifier through three separate, corresponding inlet points: PurgeOxidant Streams, Bed Oxidant Streams and Plano Oxidant Streams. ThePurge Oxidant Stream is the Oxidant Stream that is introduced to thefeedstock and enters the gasifier with the feedstock through thePressure Lock. The Purge Oxidant Stream also prevents tarry gases fromback-flowing into the Pressure Lock. The Bed Oxidant Stream enters thegasifier through inlets 11 located at the top of the gasifier. The PlanoOxidant Streams enter the gasifier through the Plano Air Inlets 31, 32located in rings around the perimeter of the Oxidation Zone 30. TheControl System monitors and adjusts each of these Oxidant Streams tocontrol the total amount of Oxygen in each zone of the gasifier and therate of Producer Gas being generated. The Control System can adjust thevolume and velocity of this Oxidant Stream to adjust for feedstockhaving differing moisture contents, bulk densities, or even because ofchanges in the BTU value of a feedstock. The Control System allows forthe changes to be made while the gasifier is in operation, so that itdoes not need to be shut down or be reconfigured.

The more Oxygen fed to the gasifier the faster the feedstock is gasifiedin the Oxidation Zone. The faster the reaction, the more Biochar isproduced and accumulates in the Reduction Zone 40.

Implementing a Control System for variable control of the grate 50 andthe Oxidant Stream in the gasifier also ensures the consistency andquality of the Producer Gas.

Thermocouples and Ceramic Lining

There are several different redundant control methods used in thegasifier, and most function as a means by which more precise control canbe achieved throughout the process. In one embodiment, an effectivecontrol method is to monitor the thermal gradient, or profile, asindicated by the temperatures of each zone. These temperatures areobtained by way of embedded thermocouples inside of the lined wall ofthe gasifier. This temperature gradient, or profile, is a very goodindicator of where each zone is and where it is moving toward within thegasifier. In one embodiment, the Control System uses this information tochange the balance of Oxidant Stream at any given zone or to physicallychange the height of the bed of Biochar in the Reduction Zone 40 by wayof the grate 50 rotation and bypass to help maintain and/or sustain eachzone above it.

One embodiment improves the consistency of the Producer Gas by liningthe entire gasifier with silica carbide, silica oxide, aluminum oxide,refractory alloy, other ceramics or another material that is stable athigh temperatures. This lining helps to evenly distribute and conductheat out from the Oxidation Band 350 and allows the use of thermocoupleswhile protecting them from the reactions occurring inside the gasifier.

The Control System may use all of the different methods and combine saidmethods into an algorithmic controller. The latter does not only allowfor redundancy throughout the Control System but also ensures muchgreater reliability and efficiency. It furthermore ensures that theProducer Gas is of constant and high quality.

The application and method of gasification described above also providesan effective way of controlling the height of the Reduction Zone 40. Aproblem in other gasifiers is that the Oxidation Band 350 is limited toone location within the gasifier, and moving it disrupts the function ofthe process substantially or destroys the gasifier. In one embodiment ofthis gasifier, the Oxidation Band 350 can move up into the PyrolysisZone 20 or down into the Reduction Zone 40 and still be controlledand/or maintained by way of where the Control System allows the OxidantStream to be placed and amount of Biochar being removed. Disruption tothe height of the feedstock, or the differential pressure across thegasifier can therefore be controlled by way of the grate 50 rotationwithout risking the Oxidation Band's 350 collapse.

Gas Produced

During operation, the gasifier will create Producer Gas having acalorific density of 125 to 145 btu/ft³. This quality of Producer Gaswill continue to be produced for so long as sufficient Oxidant Streamand suitable feedstock are made available to the gasifier. In oneembodiment, the gasifier converts between 12 and 120 tons of feedstockper day.

It is clear that while this gasifier is quite different in design thanother gasifiers, it also substantially improves the output and qualityof Producer Gas, as well as the overall efficiency of the process overother downdraft gasifiers on the market today.

High Yield Production of Biochar

As described above, the downdraft gasification device is designed toconvert as much useable energy as possible from waste feedstock tothermal energy for a variety of uses. By introducing novel changes tothe existing gasification process design, the traditional process zoneswithin the downdraft gasification device are collapsed (shrunken)creating a process through which increased feedstock throughput isachieved with higher quality (higher carbon content) and higher quantitybiochar output on a continuous basis. Novel changes to the existingprocess methodology include temperature control and feedstock retentiontime.

Temperature Control:

Drying zone temperature control is an integral function for increasedcarbon conversion in the existing downdraft gasification process.Process modeling has indicated that a drying zone temperature of 500°F.-700° F. greatly enhances the functionality of the drying zone acrossa broad spectrum of feedstocks and feedstock moisture contents. Thisultimately equates to more rapid drying of the feedstock and expansionof the remaining zones within the device which increases both mass andcarbon conversion.

By reducing the temperature requirement in the drying zone from about200° F. to 300° F., the drying zone is effectively lengthened within thedevice enabling the oxidation and reduction zones in turn to reduce inlength. This is the initial step in reducing carbon conversionefficiency and increasing total throughput. Lower temperatures in thedrying zone allow moisture to be retained within the feedstock for alonger period through the device. This moisture inhibits conversion ofcarbon to syngas and increases biochar yield.

Feedstock Retention Time:

Feedstock Retention Time (FRT) is an important parameter for controllingcarbon conversion in the existing downdraft gasification process.Retention time is adjusted utilizing both rotation speed and verticalheight of the rotating grate design. Lowering or increasing rotationalspeed of the grate coupled with an adjusting the grate height (smalleror larger area of the gap between the grate and the vertical refractorywall or refractory wall retaining ring) will control retention time offeedstock within the device. Longer retention time equates to higherconversion as more of the feedstock material is allowed to complete theconversion process to syngas. Maintaining the FRT to a range of about5-20 minutes with and an optimal time of 10 minutes optimizes theconversion of the feedstock to biochar.

Grate Rotation and Height Adjustment:

The production of Biochar is increased by adjusting the rotating speed(RPM) of the rotating grate and by adjusting the height of the grate(increasing or decreasing the area of the gap between the rotating grateand the vertical refractory wall or refractory wall retaining ring).This sets the retention time of the feedstock within the gasificationdevice. For example, reducing retention time effectively allows morefeedstock to be charged to the gasifier and lowers carbon conversion andsyngas yield which in turn results in increasing the biochar yield on acontinuous basis. This control adjustment also results in processtemperature changes (more material through the drying zone at a lowertemperature) which further reduces the size of the oxidation andreduction zones within the downdraft gasifier and allows the drying andpyrolysis zones to be extended to the full length available within thedevice. In sum, increasing the height of the gap and the RPM of therotating grate decreases the FRT and increases the biochar yield. Therange for the gap size is ¾″-2¼″ with an optimal size of 1½″. The rangefor the RPM of the rotating grate is 0.5-1.5 RPM with and optimal RPM of0.75.

Moisture Content of Feedstock:

Through manipulation of the drying zone temperature, the FRT and the gapsize and rotational speed of the grate the moisture content of thefeedstock can be optimized for high biochar yield during gasification.For a high yield of biochar during gasification, the range for thefeedstock moisture content is 15%-30% with an optimal moisture contentof 20%.

These novel process control changes create the means to allow thegasifier to switch from a highly efficient (carbon conversion) waste toenergy gasification device to a highly efficient large-scale biocharproduction device. Carbon content of the end product biochar is improvedfrom ˜75% to a content as high as >95% total carbon, and mass conversionof the feedstock is reduced from ˜90% conversion to a point as low as75% conversion dependent upon feedstock moisture content. The result isa high carbon content biochar that can be produced in quantitiescontinuously of 15% or more of the total feedstock.

FIGS. 18-21 are graphs showing data in support of the present inventionand findings of the down draft gasifier performance from a 100-day testrun limiting the drying zone temperature and adjusting the grate heightand speed.

For FIGS. 18-21, the data in summary provides both the ranges andoptimal conditions as follows:

Grate gap size:

-   -   Range=¾″-2¼″    -   Optimal=1½″

Rotating Grate RPM:

-   -   Range=0.5-1.5 RPM    -   Optimal=0.75 RPM

FRT in drying zone:

-   -   Range=5-20 minutes    -   Optimal=10 minutes

Drying zone temperature:

-   -   Range=200° F.-300° F.    -   Optimal=260° F.

Feedstock moisture content:

-   -   Range=15%-30%    -   Optimal=20%

In summary, when the feedstock retention time and temperature in thedrying zone are decreased, the moisture content of the feedstockincreases. In addition, increasing the rotating speed of the rotatinggrate and increasing the height of the gap both decrease the feedstockretention time in the drying zone. As a result, the production of syngasdecreases, and the biochar yield increases. With a steady stream offeedstock, the production of biochar can be made continuous using thepresent down draft gasification device.

Miscellaneous

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing an invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., “including, but notlimited to,”) unless otherwise noted. Recitation of ranges as valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention (i.e.,“such as, but not limited to,”) unless otherwise claimed. No language inthe specification should be construed as indicating any non-claimedelement as essential to the practice of the invention.

Preferred embodiments of this invention are described herein. Variationsof those preferred embodiments may become apparent to those havingordinary skill in the art upon reading the foregoing description. Theinventors expect that skilled artisans will employ such variations asappropriate, and the inventors intend for the invention to be practicedother than as specifically described herein. Accordingly, this inventionincludes all modifications and equivalents of the subject matter recitedin the claims appended hereto as permitted by applicable law. Moreover,any combination of the above-described elements in all possiblevariations hereof is encompassed by the invention unless otherwiseindicated herein or otherwise clearly contradicted by context.

While the disclosure above sets forth the principles of the presentinvention, with the examples given for illustration only, one shouldrealize that the use of the present invention includes all usualvariations, adaptations and/or modifications. within the scope of theclaims attached as well as equivalents thereof Those skilled in the artwill appreciate from the foregoing that various adaptations andmodifications of the just described embodiments can be configuredwithout departing from the scope and sprit of the invention. Therefore,it is to be understood that, within the scope of the appended claims,the invention may be practiced other than as specifically describedherein.

What is claimed is:
 1. A method of gasifying feedstock with a high yieldof biochar comprising: filling a gasifier with feedstock, said gasifiercomprising a plurality of conjoined and vertically positioned tubeshaving an interior wall, an exterior wall, a proximal end and a distalend, wherein the proximal end provides an inlet and the distal endprovides an outlet, a drying zone, a pyrolysis zone, an oxidation zoneand a reduction zone; drying the feedstock; igniting the feedstock tocreate an oxidation band; injecting oxidant streams into the oxidationzone using at least two rings of piano air inlets; moving feedstocksequentially from the drying zone through the pyrolysis zone where thefeedstock begins to decompose, then through an oxidation zone where thefeedstock begins to change to producer gas and then through a reductionzone where the change to producer gas is completed, the gas cools andseparates from the biochar; holding feedstock and a bed of biocharinside the gasifier using a rotating and vertically adjustable gratepositioned below the reduction zone, said position of the grate forminga variably sized bypass between the grate and the reduction zone;removing biochar through the rotating grate and the bypass; removingproducer gas through gas collection vents; and refilling the gasifierwith feedstock.
 2. The method of claim 1, wherein the temperature of thedrying zone is between 200 degrees Fahrenheit and 300 degreesFahrenheit.
 3. The method of claim 1, wherein the temperature of thedrying zone is 260 degrees Fahrenheit.
 4. The method of claim 1, whereinthe bypass is between ¾ inches and 2¼ inches.
 5. The method of claim 1,wherein the bypass is 1½ inches.
 6. The method of claim 1, wherein therotation of the grate is between 0.5 and 1.5 rotations per minute. 7.The method of claim 1, wherein the rotation of the grate is 0.75rotations per minute.
 8. The method of claim 1, wherein the feedstock isretained in the drying zone between 5 minutes and 20 minutes.
 9. Themethod of claim 1, wherein the feedstock is retained in the drying zoneis 10 minutes.
 10. The method of claim 1, wherein the feedstock has amoisture content between 15 percent and 30 percent.
 11. The method ofclaim 1, wherein the feedstock has a moisture content is 20 percent. 12.The method of claim 1, wherein the interior wall has a lining made ofmaterial that is stable at temperatures suitable for gasificationcomprising silica carbide, silica oxide, aluminum oxide, ceramic or arefractory alloy.
 13. The method of claim 1, further comprisinginjecting air into the gasifier by non plano air inlets, wherein a bedoxidant stream enters the gasifier through non plano air inlets and apurge oxidant stream enters the gasifier with the feedstock.
 14. Themethod of claim 1, further comprising pressurizing the gasifier duringoperation.
 15. The method of claim 1, further comprising simulating athroat and hearth gasifier by forming through use of the gasifier, aninduced feedstock gradient above the oxidation band and an entrainedbiochar gradient below the oxidation band wherein the tube correspondingto the oxidation zone has a middle portion that is dilated, followed bya reduction zone wherein the interior wall of the tube corresponding tothe reduction zone has a greater diameter than the tube corresponding tothe oxidation zone.
 16. The method of claim 15, wherein at least one ofthe at least two rings of plano air inlets is located around the dilatedportion of the tube corresponding to the oxidation zone and ispositioned above the plano air inlets located around the dilated portionof the tube corresponding to the oxidation zone to allow additionaloxidant streams to be injected into the feedstock.
 17. The method ofclaim 1, wherein the grate has a top face and a bottom face, the topface having a center and no right angles with respect to the verticallypositioned tubes of the gasifier, further wherein the grate is patternedwith a spiral groove that begins at the center of the top face of thegrate and spans the entire top face of the grate.
 18. The method ofclaim 17, further comprising holes in and distributed symmetricallyacross the grate, wherein the holes in the grate are elliptical-shaped,kidney-shaped or oval-shaped and wherein the bottom face of the grate isa frame further comprising a plurality of replaceable segments sittingon the frame.
 19. The method of claim 17 further comprising rotating thegrate in the opposite direction of the spiral groove and moving biocharoutward from the center of the top face of the grate to an edge of thegrate and forcing the biochar out of the reduction zone through thebypass.
 20. The method of claim 1 further comprising removing materialsthat have not gasified during operation of the gasifier through thebypass.
 21. The method of claim 1 further comprising monitoring andadjusting gasifier variables using a control system and sensors.
 22. Themethod of claim 21 further comprising holding the oxidation band at anydesired location within the gasifier by using the control system toadjust the removal rate of biochar from the grate.
 23. The method ofclaim 21, further comprising adjusting a vertical differential pressureacross the gasifier by the rotational speed of the grate, to control therate biochar is expelled from the reduction zone.
 24. The method ofclaim 1, wherein the bed of biochar is a pseudo-seal for the distal endof the gasifier.